Upholstery forming machine



) ze, 1939.; c. w. AVERY 2,184,660'

I UPHOLSTERL FGRIING MACHINE Filed Jan. 13, 1936' INVENTOR- ATTORNEY Patented Dec. 26, 1939 UPHOLSTERY FORMING MACHINE Clarence W. Avery, Detroit, Mich., assignor to The Murray Corporation of America, a-cor.

poration of Delaware Application January 13., 1936,'Serlal No. 58,859-` 5 Claims.

This invention relates to apparatus for, and a method of, preparing upholstery trim for use in connection with the manufacture of automobile seat constructions.`

More particularly the present invention relates 5 to a novel method of distributing a uniform layer of padding material upon a backing sheet, dividing the material along substantially parallel longitudinal lines to provide a tufted effect, covering the padding material with a suitable finish trim, forming the trim material to a contour substantially that desired in the finished article and stitching the finish material in position to the backing sheet, thus firmly securing isolated bodies of the padding material in position between the finish material and backing sheet.

It is a general object of the present invention to provide a machine which will substantially auto, matically, and continuously form a series of padded upholstery trim sections, which each comprise a pair of layers of fabric material with relatively isolatedsections of padding material secured in position therebetween.

Yet another object ofthe present invention consists in the provision of apparatus for accurately and eiliciently separating a substantially homogeneous relatively thick layer of padding material linto isolated sections which constitute tufts in the finished product. f t

Yet another object of the present invention consists in the provision of apparatus which is so A constructed and' arranged that it will operate vsubstantially continuously, to produce finished padded trim panels of substantially uniform composition and construction, and in which the padding mate'- rial is securely fastened in place and has been preformed to provide a predetermined desired tufted eiect.

Many other and further objects and advantages of the present invention will become apparent from the following specicatlon when considered in connection with the accompanying drawing forming a. part thereof.

1n the drawing: f

5 Fig. l is a perspective view of the complete machine, showing in detail the relativeposition of the various parts and the manner in which they are co-related.

Fig. 2 is an enlarged fragmentary perspective viewof one of the caterpillar chains which serve to form the separated sections of padding material .to the predetermined desired form and curvature, and which serve the purpose of retaining the padding material and flnish'trim in position durin the stitching operation.

(el. i12- 2) Fig. 3 is a sectional perspective view of a conventional automobile seat, illustrating the improved finish trim panel applied thereto.

Fig. 4 is a fragmentary perspective view, illustrating in detail the stitching mechanism and the manner in which the finished trim panel is re- 5 tained in position during the stitching operation.V

Fig. 5 is a sectional view taken substantially on. the line 5-5 of Fig. 3, illustrating the finished upholstery trim panel.

Fig. 6 is an enlarged fragmentary perspectivev l "view, illustrating. in detail the mechanism which serves to grip the marginal edge of the backing sheet as it travels through the machine in order to maintain this sheet under the proper tension and position the same properly with respect to the frame work of the machine along which it travels.

Fig. 7 is an enlarged fragmentary perspective view of the cutter knives, which serves to divide the padding material into the predetermined sections. .so Fig. 8 is an enlarged fragmentary perspective view of a modified form of apparatus for dividing the layer of padding material into predetermined sections. t

With more' particular reference to the drawing, the apparatus in general comprises a 'work table Il) of substantial length and of la width sul.- ciently wide to accommodate the Width of the upholstery trim panels which it is desired to pro'-` duce. Mounted in stationary position with respect to the work table I0, at one end thereof, is a frame work I I, which serves to support a reel I2 of burlap I3 or other suitable backing material. This burlap web I 3 is fed from the reel I2 by means of a' pair of feed. rolls I4 and passesv over an idle roller I5, the upper surface of which lies substantially in the plane of the upper surface of the tablev I0.'

The web I3 is fed longitudinally along the table and at the rear end of the table are provided a pair of sprocket pulleys I8, around which are fed caterpillar chains I9, each composed of gripping links 20. which are of a construction adapted to v tially vertically disposed' upper jaws 23. Riehl of the jaws 23 is provided with an upwardly extending latch 24,4 preferably formed integrally therewith, which engages a. cam plate 25, mounted in stationary position on the table IIJ. As is clearly seen in Fig. 6, the cam plate 25 serves to move the jaw member 23 inwardly with respect to the jaw member 22 at about the time the marginal edge of the backing web I3 enters between the jaws. This cam 25 serves to retain these jaws in open position until the marginal edge of the backing web has entered the full depth between the jaws and then the latch 24 Will slide forwardly past the front end of the: cam surface and allow the jaws to'swing by force of gravity, down into engagement with the backing sheet I3, thus rmly securing this sheet between the jaws 23 and 22. It will be appreciated by reference to Fig. 6 that the jaws are of such construction that subjection of the backing sheet to lateral tension serves merely to tighten the grip of the jaws 22 and 23 on the marginal edge of the backing` sheet.

As has been pointed out above, these caterpillar chains I9 preferably extend throughout the entire longitudinal length of the table and it will be appreciated therefore that the backing web of burlap I3 is gripped in its marginal edges and maintained under proper tension and accurately in position throughout the entire length of the table and consequently throughout the entire period when the various forming and treating operations are performed on the backing sheet.

Means are provided for distributing a substantially homogeneous uniform layer of non-woven fibrous padding material upon the backing web I3. While any suitable means may be used for accomplishing the results desired in this connection, I have shown by way of illustration one preferred method and apparatus' for accomplishing this result. The apparatus disclosed generally comprises a Garnetting machine 30, into which a suitable supply of non-woven fibrous material may be fed. As is conventional in apparatus of this general type, the cutters and combs of this Garnetting machine serve to tear up the fibers and distribute them at random substantially in a uniform non-woven layer as they are fed out of the machine by means of an endless conveyor belt 3l operating upon a pair -of pulleys or rollers 32. 'Ihis web of padding material, designated as 33, is fed from the conveyor belt 3| to an oscillating conveyor belt 35. The conveyor belt is mounted upon a pair of rollers 36, which are journaledfor rotation in a frame work 31 which is pivoted to the frame work carrying the conveyor belt 3I. The lower end ofthe frame work 31 is provided with a pair of brackets 40 which have journaled thereon a plurality of rollers 4I which serve 4to engage a pair of transversely extending trackways 44 extending throughout the entire transverse'width of the work tablel I0. Suitable sprocket chains 45 serve to drive not only the conveyor belt 35 but also serve the purpose of reciprocating the frame -work 31 transversely -with respect to the work table I0 in order that the layer of nonwoven padding material will be distributed substantially uniformly on the backing web I3 which -passes longitudinally along the table.

.It will be appreciated that the reciprocation of the frame work 31 is relatively rapid with respect to the longitudinal movement of the backing yweb I3 and consequently a relatively heavy, unitributed upon the surface of the backing sheet I3.

While the padding material generally used for constructions of this general kind is of such a nature that it is not necessary to adhesively secure it to the backing web, if desired the web as a whole may be covere'd with a film of liquid adhesive prior to the application of the padding material and the padding material may be compacted into engagement with the backing web after the fibrous material has been distributed thereon substantially in the manner described in detail in applicants prior co-pending application, Serial No. 54,121, filed December l2, 1935, and assigned to the assignee of the present invention.

In order that the padding material, which after distribution by the conveyor system described above lies in substantiallya layer of uniform.

thickness, may be divided, means are`provided for separating the padding material along substantially uniformly spaced parallel longitudinal lines. While various means may be employed for accomplishing this general result, by way of illustration I have shown a-method which has been found particularly satisfactory for this purpose.

While it may be appreciated that a pair of cooperating rollers, one of which has al groove to receive the other, may be utilized for the purpose of separating the matted layer of brous material into relatively isolated strips, the present application discloses the use of toothed rotary knives for accomplishing this purpose.

A rotary shaft is mounted in suitable bearings and extends transversely of the framework.

Means, not shown, are provided preferably for driving the shaft at relatively high speed. A plurality of rotary knives 5I are secured to the shaft 50 for rotation therewith and it will be appreciated that these knives may be spaced one from another in accordance with the width of the tuft desired .to be produced upon the finished upholstery trim panel. Inasmuch as the padding material is very tough, and it is highly desirable that the segregated areas be separated slightly one from another, means are preferably provided to oscillate the shaft 50 in a direction transverse of the travel of the burlap backing sheet and vpreferably axially of the axis of rotation ofI the shaft 50. While any suitable means may be utilized for the purpose of accomplishing this transverse oscillation, I have illustrated by way of example an electric motor 53 mounted upon a suitable support in the frame work I0 of the table, which serves to oscillate a pivoted link 54, which is in engagement with the end of the shaft 50. It will be appreciated that as the shaft 50 is rotated at relatively high speed, and oscillated longitudinally of its axis, the layer of padding material will besevered by the rotary knives 5I and divided into parallel isolated areas, which are slightly separated one from the other, and lie longitudinally along the backing web I3. It has been. found preferably to form the teeth on the knives or cutters 5I of involute form, in order that the action thereof upon the padding material will be a cutting rather than a tearing action, and the involute tooth structure of these knives has been found particularly desirable lin. asmuch as it effectively serves to prevent an accumulation of fibrous material in the teeth of knives and a consequent clogging thereof, thus preventing an impairment of their cutting action.

After the paddingmaterial has been divided by the knives 5I into a plurality of parallel seczov - tions,.sections ofJfabric-iinish material i` work I0 and e u longitudinal lines in the spaces betweenthe strips GI are placed upon the padding material and it willbe seen by reference to Fig. 1 that the transverse width of these finish sheets must be substantially 5 greater than the width of the webbing backing sheets 13. This is necessary inasmuch as the,

backing sheet is maintained in tension'ed position and the surface finish layer of fabric` must be shaped to conform tothe -padding material and 10. consequently as it is s shaped there is a substantial reduction in the effective width thereof.

Suitable means are provided for forcing the finish trim material down in between the strips i of pa ding material lying on/tl'ie backing sheets.

l5 Whil thismay be accomplished in any suitable manner, I have illustrated in Fig. 1 a preferred method of accomplishing this result, which has been found particularly effective. A plurality ofI transverse shafts- 65 are -journaled in the frame d transversely thereof. These shafts have m serve to engage the surface of the finish material and force it'down b etw/een the strips of padding material. It will be'apprciated that. the spacing 6 of these rollers is substantially identical with the spacing of the cutters 5| described above and consequently as the nish fabric material is engaged by these rollers, the rollers serve to force `the fabric material downin between the sepaa0 rated strips of padding material and satisfactorilytension this material over the surface of the tufts to provide a neat, attractive, uniform nish tothe upholstery panel as ai whole. Itis noted that the rearward shaft 65 carries three rollers 35 which are adapted to engage the central portion of the nish material irr order that this material may be gradually drawn laterally inward to assume the conformation of the padding material and to' permit the desired gathering of the material and yet maintain theflnished material at proper tension. The forward shaft 85 contains additional rollers which serve to force further portions of theiinish material down in between the strips o'f padding until the forwardmost shaft 65 has a set of rollers equal in number t'o the set of knives for separating the padding material and` consequently rtwin be seen that es tire backing sheet as -a whole passes out from unde eath this gang of rollers, the finish fabric mater al been formed to the curvature ofthe strips of paddrical curvature adapted to engage the surface ofa tuft in the upholstery trim panel in order to-y rmly position the fabric surfaces trim-in positionwith respect to the padding andbackingsheet *during the stitching operation hereinafter de scribed. AS is clearly'llllstrted in Fig.'4 ofthe 65 drawing, these caterpillar chains serve to form -the padding material to thedesired rounded curvature and serve accuratelyto retain this padding material and fabric finish in accurate :position with respect to the backing sheets d ur'- 76 ing the stitching operation.

LA plurality of sewing machines, comprising aguide bar 14, a ertically reciprocable` sewing head 15, 'and a n finish material to the backing sheets I3 along aragoneted thereon rollers 66, which e Riserve to stitch the 'fabric of padding. The chains 1I serve to forni the padding material to the ldesired rounded curvature and it will be appreciated that as the web .emerges from the forward end of the table,

. the. upholstery trim panel will be substantially completely form'ed'andall that is necessary is to cut oif the'backing web adjacent the terminal edges of the finish-sections which have been se- ,t cured thereto.

It has been found.that'the above described-apfactory rapid and emclent means for constructing upholstery trim panels and that the trimY panels prodquced thereby are of exceedingly attractive uniform and satisfactory construction, being par-- paratus and method provides an extremely satis' ticularly neat in appearance and having the padi dingmaterial firmlyl secured therein and uni'- iormly distributed. A t

While as has been stated above, the rotary involute cutter knives 5I 'provide an extremelysat-l isfactoryA means for separating the padding material into relatively log isolated longitudinal strips, I have illustrated in Figure 8 by way of.

modification a modied means by which thepadding material may be separated into the desired longitudinal'strips. In this form of the inven-4 tion, the padding material 80 is fed through the machine and underneath a plurality of belt members 8I,which engage b oth the upper .and lower' side of the padding web. It will-be noted thatv two'of these belt` members B2 and 83engage each of the strips'of padding material and it is'appreciated by reference to Fig. 8 that each of ese belts extends at an inclined angle to the lo gitudinaldirection of movement of the padding sheet as a whole. The divergence of these belt assemblies serves to tear' the padding upon substantially parallel longitudinal lines and serves also to form the torn longitudinally extending strips into substantially the desired conformation for use in. upholstery iinsh panels.

t will be appreciated that the form'of the invention described above is merely illustrative of the generic inventive concept presented and that further modifications, substitutions andchanges may be made therein without departing from the spirit of the invention, the scope of whichis commensurate with the appended claims. -v

VWhat is claimedvr is: Y v 1. The method of preparing upholstery, which comprises vapplying `a substantially uniform layer of padding material to a backing sheet, dividing the paddingV material along substantially parallel lines to form strips ofv padding jmaterial while supported on said backing sheet', subsequently. covering said padding material 'with 'a fabric finish material, forcing-.the fabric material downwardly between lsaid strips 'ofpadding material and retainingV said .fabric .material in position while verticeuy stitcmngsaid iinisn materiel te said backing sheets.

2. The method of preparing upholstery, which comprises applying a substantially uniform layer of padding material toa backing sheet, dividing tire-padding material aicngsubstantieuy samuel longitudinal lines to formstrips of padding ma-v terial while supported on said backing sheet, subsequently covering said -padding material with a. fabric finish material, forcing said fabric matelrial downwardly between said strips of padding material in the central portion of said backing sheets, and successively forcing said nish mate''A rial downwardly between said strips, said forcing Aprogressing' laterally outwardly Afrom the center to t' ler suabecxingsneets, anamnesifg ly stitching said nish material to said backing sheets.

3. The method of preparing upholstery, which comprises applying a substantially uniform layer of padding material to a backing sheet, dividing the padding material into strips of padding material along substantially longitudinal lines While supported on said backing sheet, subsequently covering said padding material with a fabric nish`material, forcing said fabric finish material between the strips of padding material in the central portion of said backing sheets, successively forcing said fabric nish material between said strips laterally outward from the central portion of said backing sheets, the while retaining said fabric material between the strips in the central portion of the sheets, and vertically stitchingA said finish material to said backing sheet between said strips.

4. A machine for forming upholstery ofthe type including a backing webb, padding material, and a fabric nish webb, including, in combination, a work table, means for moving a backing webb along said work table, means for distributing a substantially uniform. layer of padding l material on said backing webb, means for sever- ,and a fabric finish web, a work table, means for moving a backing webb along said work table, means for distributing a substantially uniform layer of padding material on said backing webb; means for severing said padding material along substantially parallel longitudinal lines to form a plurality of strips of padding material while the same are supported on said backing web, and means including a series of spaced rollers for forming a sheet of finish material to -the conformation of said strips of padding material.

CLARENCE W. AVERY. Y 

